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In the world of medical devices, HVAC, and general machinery, gaskets have a crucial role. They’re basically mechanical seals, which can have many functions; from sealing out dust, water, and debris to stopping EMI/RFI, by sealing two mating surfaces. While most gaskets are seals by nature, they can be manufactured differently, depending on your needs. For instance, some gaskets are manufactured with water jet cutting, while others are created with die cutting.   

But what are the biggest reasons to choose die-cut gaskets? Let’s first look at how die-cut gaskets are produced and then move on to some of the most common benefits of die-cutting gaskets.

How Are Die-Cut Gaskets Created?

In order to create a die, a sharp cutting tool is bent into a part’s outline and integrated into its base or board for support. When it’s time to create parts, a hydraulic press cuts through the raw material while it is fed through a die-cutting machine (think of a giant cookie cutter). This process leaves your product even, clean, and in line with your desired measurements.

The Benefits of Die-Cut Gaskets

Cost Effective 

With die-cutting, you can create parts quickly and effectively.  It is quicker to produce parts and therefore more cost-effective than something that takes longer like waterjet cutting.

Follow Regulatory and Safety Standards

If you work in a field that requires strict adherence to regulatory standards, die-cut gaskets can be quite helpful. At American Flexible Products, our engineers can help you choose designs and materials that adhere to the standards you must meet. In doing so, your operation remains lawful, and your customers stay safe.

Withstand Pressure and Heat

Gasses and fluids that run through machinery can be scorching hot. With heat comes thermal expansion, which creates pressure. This combination can be harmful on parts but die-cut gaskets can be resistant to both pressure and heat, keeping your parts safe.


At American Flexible Products, our technicians have the ability to create a perfectly shaped product every time by using die-cutting techniques. We know this because our materials techs watch over the process with precision and focus. Even with runs of one hundred, one thousand, ten thousand, or more, you can be sure that each part is cut exactly to your design specs every single time.

When Should You Use Die Cutting?

Die cutting can be used to produce anything from gaskets to adhesive mounting pads. Of all the different ways to shape and cut materials, flatbed die-cutting is most useful when:

  • Your order quantity is 100+ pieces per year
  • You want your parts with or without adhesive
  • Tooling is inexpensive and quickly produced
  • You need a cost-effective manufacturing option

To see a full list of flexible materials that our engineers cut, click here. Don’t see your material on that list? Let us know. With more than 30 years of experience in custom fabricating foam, rubber, plastics, and other flexible materials, chances are we’ve used it before.

The Trusted Name for Die-Cut Gaskets

If you’re facing an unusual gasket problem or simply need a part that other shops can’t produce, our engineers are here to help. Whether you need insulation, gaskets, or seals, die-cutting is a great way to cut the shape and materials you need. And because almost any flexible material can be die cut, our team can shape the foam, silicone, and rubber parts you need most.

Wondering if flatbed die cutting is suitable for your project? Contact us today to speak with one of our engineers. We’ll help you decide which type of shaping is best for your project.

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